Using Roadware matchCrete Clear, cement powder, and rock to make exposed aggregate concrete spall repairs.
This driveway was seriously damaged from deicing snowmelt treatments. I simply routed out the perimeter of each of the damaged areas. I then thoroughly power washed to remove all dirt and loose debris and allowed the area to dry. I mixed up four separate batches of Matchcrete mender with 1/4”pea gravel seeded on top. I then applied a small amount of fine sand before the surface had hardened. The homeowner was extremely pleased with the finished results!! Thanks so much to the folks at Roadware Inc for their insight and positive support on this project!! Please note, I will diamond cut, and route open the original joints after full cure time.
Remove loose material and create a shelf on both sides of the joint with a minimum profile of 1.5” deep and 2” wide on each side. Vacuum and thoroughly remove dust and contaminates.
Create a repair base by filling repair area halfway to grade with bulk mixed 10 Minute Concrete Mender™ combined with 10-20 grit silica sand.
Use a ratio of 1 Part mixed Concrete Mender to 2 parts silica sand. Up to 1/2 part additional sand may be added during application to assist with troweling and placement. Be sure to leave the lower half surface rough and sand covered to accept the next layer.
EXAMPLE
1 Qt side A,
1 Qt Side B,
4 Qts 10-20 silica sand,
Up to 1 quart additional sand as needed.
Once the first layer sets and turns grey, continue with an additional layer up to flush with the surface.
The mixed material should always be resin rich and the sand should be fully saturated when applying to the repair area.
For extra surface strength, 30 grit aluminum oxide may be broadcast and troweled in place on top as the materials start to gel in about 5 minutes after placement. Allow to fully cure and grind flush within 24 hours. OPTIONAL: Re-saw the contraction join
A new freezer floor coating developed by Roadware, Inc. can stop concrete dusting and restore freezer warehouse floors. Concrete dusting in your warehouse floor is a difficult challenge. Dusting is when the concrete surface deteriorates to powder due to heavy traffic, improper placement of the original concrete, mix design failure or a number of other reasons. Surface dusting can lead to hazardous conditions for personnel, unsanitary conditions and product contamination. If the concrete is solid beneath the surface, these slabs can be made serviceable with specialized coatings. Coating slabs like this is even more challenging in a working freezer where temperatures are typically -20 degrees F (-29C).
Dusting concrete floors in a freezer can lead to unsafe and unsanitary conditions as well as contamination of product.
Concrete dusting can lead to the complete breakdown of the concrete wearing surface. Pallet jacks and forklifts can grind down the concrete allowing silica dust to become airborne and causing a health hazard.
Freezer warehouse floor with failed topping slab and dusting concrete.
Disbonded topping slabs and epoxy coatings can also create a hazardous dusting situation.
Freezer floor being prepared for coating with Roadware Freezer Coating by grinding the surface flat with metal grinding pads.
Here concrete polishing equipment with metal grinding pads are used to remove the dusting surface of the concrete back to a solid surface.
Freezer floor being prepared for coating with Roadware Freezer Coating by grinding the surface flat with metal grinding pads.
Hand grinders can also be used to remove the dusting surface. Dust collection systems are used to collect hazardous silica dust.
Roadware Freezer Floor Coating is easily mixed in a pail using a ratio of 1 part ISO, 1 part POLY and 1 part manufactured sand.
Roadware Freezer Floor Coating is mixed at a ratio of 1:1:1:
One quart A
One quart B
One quart 4030 grit silica or manufactured quartz sand.
Combined on a pail and mix with a paint stick or 10 seconds. Apply immediately.
Coverage rate shown here is approximately 2.5 Meters Sq per mixed liter.
Keep materials at outside the freezer at about 60-70 degrees before mixing. Floor and air temperatures in the freezer for this project were -4 degrees F (-20C).
Craftsman trowel down a thin sealer coat of Roadware Freezer Floor Coating on to a prepared concrete floor at below freezing temperatures.
A single trowel down application is all it takes to provide a new surface to the concrete and good working floor. Product is applied at freezer operating temperatures. Product cures in several hours depending on the temperature and odor is very slight. Stand-up trowels may be used as well.
See craftsmen with Concrete Dr in Seoul, Korea apply Roadware Freezer Floor Coating at -4 degrees F (-20C) . A propane torch is used to remove flash frost just before application.
Freezer warehouse floor coated with Roadware Freezer Floor Coating.
Full warehouse traffic can resume in 10 hours after application.
Freezer floor coated with the Roadware Concrete Mender Freezer Coating System. This resilient coating can be applied at freezer operational temperatures and cures within hours.
Floors treated with Roadweare Freezer Floor Coating are resilient and serviceable once again.
Product: Roadware Freezer Floor Coating
Features:
Low Viscosity
Easy Mixing
Fast Curing in sub zero applications
Very low odor
Very low VOC’s that polymerize into the material.
Benefits:
Freezer floors can be repaired or coated while operating.
Can be applied in odor sensitive areas.
Easy trowel down application.
Warehouse traffic can resume in 12-24 hours depending on temperature.
Uses:
Coating freezer floors to reduce dusting and improve riding surface.
Repairing cracks, joints, and spalls in freezers.
Limitations:
Products cures a translucent natural amber. Dry colored pigments may be added to the final mixing process if needed.
Surface must be, clean, dry and free of frost.
Frost and moisture must be removed with a propane torch or electric heated air just before application.
Excess moisture can cause the product to whiten in high moisture areas and will cause an inconsistent look.
Roadware Freezer Floor Coating is available on a special order basis at this time. Call 800-52-7623 for more information.
Kelton Glewwe is Vice-President of Marketing for Roadware Incorporated and an original founding partner of the company. Kelton has set up sales and distribution networks for Roadware construction products in over twenty countries around the world. He has worked on projects ranging from automated freezer warehouses in Washington to 100 year old railroad piers in New York and Airport Runways in Hong Kong. Kelton is a graduate of the University of Saint Thomas and lives in Inver Grove Heights, Minnesota.
Join me, Kelton at Roadware at @ICRIorg’s Virtual Fall Convention #ICRIFall20. I’ve been selected to present in a product demonstration, Less Invasive Crack Repair for Concrete Floors and Structures on October 13, 2020. 2:40 – 3:10PM CST. See a preview of the presentation on YouTube. Learn more about the virtual convention here.
Roadware is a proud member of the International Concrete Repair Institute.
Here is the Roadware Concrete Mender One Page Pitch. Things you need to know when considering, recommending, specifying, and using Roadware 10 Minute Concrete Mender™
Full depth crack repair in warehouse floors usually involves cutting open the cracks with dry diamond saws. This is a slow process and creates a lot of hazardous silica dust that needs to be mitigated. Repair contractors at an Amazon Warehouse project are using an innovative way to repair cracks in the floor without the traditional cut and fill methods.
The problem:
Some people question why these types of cracks should be repaired. Cracked floors in industrial and commercial settings are a liability. The cracks will continue to get larger as wheeled traffic starts to crush the sidewalls. (More) Cracks will also fill with dirt and debris creating a hard to clean surface. Roadware 10 Minute Concrete Mender™ is a structural polyurethane that will restore load transfer and can bring a floor back to original serviceability.
This three level Amazon Warehouse developed thousands of linear feet of shrinkage cracks prior to being places into service. Roadware 10 Minute Concrete Mender will be used to repair them.
This floor presented thousands of feet of shrinkage and stress cracking. The cracks were all fairly clean without excessive foreign debris or dirt at time of repair.
The Plan:
Use sacrificial vinyl weatherstrip to make a dam parallel to the cracks that will hold Roadware 10 Minute Concrete Mender™ in place while it soaks down into the cracks. Concrete Mender™ is nearly water thin when mixed and will flow easily deep into open cracks. Since Concrete Mender™ will start to gel up in 5-7 minutes, it will naturally self-seal the bottom of the crack as it cures. It sometimes takes three of four light pours of material, but it will fill the crack completely and start the structural Microdoweling™ process. Microdoweling™ is how Concrete Mender™ uses low surface tension and molecular attraction to penetrate concrete surfaces and locking into the aggregate and rock matrix.
No-cut crack repair with Roadware 10 Minute Concrete Mender™ uses removable peel-and -stick weatherstrip to form a temporary well that holds the Concrete Mender in place while it soaks down into the crack.
Roadware 10 Minute Concrete Mender injected deep into cracks using the Roadware Easy Injection System.
Wehtherstrip is used to hold Roadware 10 Minute Concrete Mender in place while it soaks deep into cracks.
Application:
With Concrete Mender™, expensive pumps and equipment is not needed. Once cracks are vacuumed and the surface is cleaned. The weatherstrip dam can be applied. Roadware 10 Minute Concrete Mender™ can be mixed on one gallon batches by hand in a bucket and poured directly into the cracks. Additional manufactured sand can be added for larger cracks, but it is not recommended for this type of repair. See more here: Concrete Mender Bulk Application Instructions
Pour equal parts A and b into a mixing container and mix for about 15 seconds with a mixing stick.
Crack repairs are filled with Roadware 10 Minute Concrete Mender to refusal and the excess is removed.
When the Concrete Mender™ cures in about 10 Minutes at 72 degrees F (21C) , the weather stripping and excess material can be shaved clear or ground smooth with standard equipment.
Roadware 10 Minute Concrete Mender filles hairline cracks completely using the dam and flood method. No cutting is needed.
After buffing and clearing excess material, floors can be returned to service immediately.
Finished concrete crack repair blend in nicely at an Amazon warehouse using full depth Roadware 10 Minute Concrete Mender™.
Additional buffing and service traffic will blend the repairs even more into the surrounding concrete.
Roadware 10 Minute Concrete Mender Technical Data Sheet
Roadware stands ready to supply immediate concrete repair needs for warehouses, cold chain logistics, manufacturing, and supply. Repairs can be made with almost no downtime and under operational conditions. Please call 1-800-522-7623 or 1-651-457-6122 to be connected with our worldwide network of distributors waiting to assist. Or, send email to sales@concretemender.com
We ask that visitors to Roadware Headquarters in South St Paul, MN, or any of our Roadware Distributors, call the location ahead to verify operating hours and local conditions.
